Study on Wire Rod Drawing Process Using the Rotating Die

2016 ◽  
Vol 716 ◽  
pp. 63-67 ◽  
Author(s):  
Gow Yi Tzou ◽  
Dyi Cheng Chen ◽  
Shih Hsien Lin
Keyword(s):  
Velocity Field ◽  
Material Flow ◽  
Effective Strain ◽  
Fem Simulation ◽  
Cold Drawing ◽  
Drawing Process ◽  
Drawing Force ◽  
Wire Rod ◽  
Forming Characteristics ◽  
Deform 3D

This study proposes a cold drawing technology of wire rod with rotating die; it carries out an FEM simulation on rotating drawing using DEFORM-3D commercial software. Frictions among the die and the wire material are assumed as constant shear friction. The effective stress, the effective strain, the velocity field, and the drawing force can be determined from the FEM simulation. In this study, effects of various drawing conditions such as the rotating angular velocity, the half die angle, the frictional factor, the die filet on the drawing forming characteristics are explored effectively. From this FEM simulation, it is noted that the rotating die effect can reduce the drawing force and increase the material flow.

scholarly journals Forming parameters optimizations with drawing force and die stress in wire rod drawing using rotating die under Coulomb friction

2018 ◽  
Vol 185 ◽  
pp. 00025
Author(s):  
Ing-Kiat Tiong ◽  
Un-Chin Chai ◽  
Gow-Yi Tzou
Keyword(s):  
Taguchi Method ◽  
Coulomb Friction ◽  
Effective Strain ◽  
Fem Simulation ◽  
Frictional Coefficient ◽  
Simulation Software ◽  
Drawing Force ◽  
Wire Rod ◽  
Forming Parameters ◽  
Die Stress

An optimization research is performed on the related forming parameters of wire rod drawing through a rotating die under Coulomb friction. The optimization research is conducted through finite element method (FEM) simulation combined with Taguchi method. There are two drawing characteristic optimizations have been carried out. They are the optimizations with drawing force and die stress. The forming parameters considered in this study are half die angle, frictional coefficient, die fillet, and rotating angular velocity of the rotating die. The same procedure is carried out in both optimizations. The geometrical models of the wire rod, top die and rotating die are constructed firstly in SolidWorks and imported into the FEM simulation software named DEFORM 3D. With the aid of Taguchi method, the simulation experiments are carried out. The results such as drawing force, die stress, and the corresponding signal-to-noise (S/N) ratio are obtained and compared. The influence rank of the forming parameters and the optimal combination of parameters are obtained through the response table for both optimizations. The results such as effective stress, effective strain, velocity field, drawing force, and die stress are studied. The results show that the minimizations of drawing force and die stress are successfully achieved.

Drawing Force Optimization Research on Forming Parameters of Drawing Wire Rod with Rotating Die under Coulomb Friction

2018 ◽  
Vol 920 ◽  
pp. 3-9
Author(s):  
Un Chin Chai ◽  
Gow Yi Tzou ◽  
Ing Kiat Tiong
Keyword(s):  
Taguchi Method ◽  
Coulomb Friction ◽  
Effective Strain ◽  
Fem Simulation ◽  
Simulation Software ◽  
Optimal Parameters ◽  
Drawing Force ◽  
Force Optimization ◽  
Forming Parameters ◽  
Deform 3D

An optimization research based on the drawing force is done on several forming parameters of metal rod drawing through a rotating die under Coulomb friction. The metal rod and the rotating die are constructed in SolidWorks and imported into FEM simulation software named DEFORM 3D. In this study, the FEM simulation is carried out by using DEFORM 3D combining with Taguchi method to explore the effective stress, the effective strain, and the velocity field. The influence rank of parameters to the drawing force is obtained, and the optimal parameters’ combination is determined by using Taguchi method. Results show that the optimization of drawing force is achieved and the minimum drawing force is successfully obtained.

Variation of Residual Stresses in Drawn Copper Tubes

2008 ◽  
Vol 571-572 ◽  
pp. 21-26 ◽  
Author(s):  
Adele Carradò ◽  
D. Duriez ◽  
Laurent Barrallier ◽  
Sebastian Brück ◽  
Agnès Fabre ◽  
...  
Keyword(s):  
Neutron Diffraction ◽  
Residual Stresses ◽  
Material Flow ◽  
Cold Drawing ◽  
Axisymmetric Deformation ◽  
Tube Length ◽  
Inhomogeneous Deformation ◽  
Drawing Process ◽  
Process Step ◽  
Residual Strains

Seamless tubes are used for many applications, e.g. in heating, transport gases and fluids, evaporators as well as medical use and as intermediate products for hydroforming and various mechanical applications, where the final dimensions normally are given by some cold drawing steps. The first process step – piercing of the billet, for example by extrusion or 3-roll-milling - typically results in ovality and eccentricity in the tube causing non-symmetric material flow during the cold drawing process, i.e. inhomogeneous deformation. Because of this non-axisymmetric deformation and of deviations over tube length caused by moving tools, this process step generates residual stresses. To understand the interconnections between the geometrical changes in the tubes and the residual stresses, the residual strains in a copper tube had been measured by neutron diffraction.

Using 2D/3D FEM Simulation to Determine Drawing Force in Cold Drawing of Steel Tubes with Straight Internal Rifling

2020 ◽  
Vol 304 ◽  
pp. 121-125
Author(s):  
Martin Necpal ◽  
Mária Kapustová ◽  
Maroš Martinkovič
Keyword(s):  
Fem Simulation ◽  
Cold Drawing ◽  
Drawing Force ◽  
Forming Process ◽  
3D Fem ◽  
Steel Tubes ◽  
Cold Forming ◽  
Cold Draw ◽  
Seamless Steel Tubes ◽  
Seamless Steel

The most comprehensive steel tube portfolio is used to produce all kinds of modern energy production and the corresponding auxiliary unit such as boilers and heat exchangers. Multi-rifled seamless steel tubes are distinguished by maximum pressure, heat resistance, strength and durability. Production of multi-rifled seamless steel tubes by cold draw process using multi-rifled mandrel is quite a new technology. Shape and dimension of the drawing tool depend on drawing tube reduction degree, i. e. on the original diameter of the initial tube and final diameter of the tube. The technology of drawing tubes is influenced by process parameters, dimensions of tools and cold forming process conditions. Optimization of the whole forming process naturally involve the FEM analyses and simulation. One of the most important information of the cold drawing process is the load stroke of the tools. The contribution is concerned at the usability of FEM simulation on an evaluation of cold draw forming process condition and prediction of load stroke of the forming tools. DEFORM 2D/3D FEM software is used to compare the result of the drawing force and to determine the appropriate methodology to set FEM simulation of cold forming.

FEM Simulation on Rotating Piercing Process with Coulomb Friction

2013 ◽  
Vol 284-287 ◽  
pp. 127-131
Author(s):  
Hsiang Yu Teng ◽  
Gow Yi Tzou ◽  
Yeong-Maw Hwang
Keyword(s):  
Coulomb Friction ◽  
Effective Strain ◽  
Fem Simulation ◽  
Frictional Coefficient ◽  
Work Piece ◽  
Shearing Force ◽  
Fem Model ◽  
Blank Holder ◽  
Inner Diameter ◽  
Deform 3D

This study proposes a new piercing technology with rotating punch; it carries out an FEM simulation on rotating piercing process using DEFORM-3D commercial software. Frictions among the punch, the blank holder, the dies and the work-piece material are assumed as Coulomb friction, but can be different. The surface of the inner diameter, the effective stress, the effective strain, velocity field, damage, burr and the shearing force can be determined form the FEM simulation. In this study, effects of various piercing conditions such as the clearance, the punch nose angle, the frictional coefficient, the rotating angular velocity, the shearing force, and burr on shearing characteristics are explored effectively to realize the feasibility of FEM model.

scholarly journals FEM simulation analysis of wire rod drawing process using the rotating die under Coulomb friction

2017 ◽  
Vol 123 ◽  
pp. 00033
Author(s):  
Gow-Yi Tzou ◽  
Un-Chin Chai ◽  
Chao-Ming Hsu ◽  
Hung-Ying Hsu
Keyword(s):  
Coulomb Friction ◽  
Simulation Analysis ◽  
Fem Simulation ◽  
Drawing Process ◽  
Wire Rod

Computer Simulation of Aluminum Conductors Drawn in High Speed

2013 ◽  
Vol 834-836 ◽  
pp. 1567-1570
Author(s):  
Ming Xue Yang ◽  
Jing Tian Luan ◽  
Tian Guo Zhou ◽  
Xue Fei Zhang
Keyword(s):  
High Speed ◽  
Cold Drawing ◽  
Drawing Process ◽  
Stress Strain ◽  
Drawing Speed ◽  
First Pass ◽  
3D Software ◽  
Distribution Of Stress ◽  
Deform 3D ◽  
Head Line

Drawing speed is one important process in production over-head line, deform 3d software is used to simulate the drawing process. The distribution of stress-strain and temperature in different drawing speed with die angle and friction coefficient was investigated. The results shows that the aluminum conductors can be used in high speed drawing when die angle, drawing speed and frication coefficient of first pass is about11~13 degrees, 4~6m/s and 0.08~0.10 respectively, the uniformity of stress-strain and temperature is better for producing good quality over-head wires with high cold-drawing speed.

scholarly journals Analysis of Manufacturing Bimetallic Tubes by the Cold Drawing Process

2016 ◽  
Vol 61 (1) ◽  
pp. 241-248 ◽  
Author(s):  
D. Halaczek
Keyword(s):  
Solid State ◽  
Wall Thickness ◽  
Material Flow ◽  
Ferrous Metal ◽  
Cold Drawing ◽  
Drawing Process ◽  
Technological Parameters ◽  
Components Analysis ◽  
Copper Aluminum ◽  
Layer Composition

Drawing processes apply to obtain the bimetallic tubes from the different metals and alloys, combined in the solid state, which significantly affects the specificity of this process. The manufacturing of bimetallic tubes by drawing process depends on many factors which include: preparation of the surface of materials joined in the solid state, the geometric parameters of the working tool, technological parameters of the drawing process (drawing speed, type of lubricant, the use of back pull etc.). Generally, the cold drawing process of producing the bimetallic tubes refers to metals which have high ductility (copper, aluminum, etc.). The tube sinking (tube drawing without a mandrel) of bimetallic tubes together with joining them at the interface of the two metal in the solid-state is applied for tubes of the diameter range between 6 to 20 mm and based on of the reducing the diameter of the tube. However, a slight increase of wall thickness ca. 0.05 ÷ 0.10 mm can appear, which is not dangerous phenomenon in case of producing the bimetallic tubes by joining in the solid-state. The aim of the research was to investigate the technology of tubes drawing process from non-ferrous metal, drawing process of bimetallic tubes and the production of bimetallic tubes in layers composition: cooper Cu-ETP - brass CuZn37 and CuZn37 brass - copper Cu-ETP in the tube sinking process. The research program included: production of bimetallic tubes with a different composition (Cu- ETP-CuZn37 and CuZn37-Cu-ETP) and a different percentage of the cross-section components; analysis of changes of tube wall thickness and the layer composition of the bimetallic tube, based on measurements on the workshop microscope; analysis of the material flow in the process of the bimetallic tubes production based on the measurements results of a profilograph CP-200.

Influence of Die Geometry on Drawing Force in Cold Drawing of Steel Tubes Using Numerical Simulation

2016 ◽  
Vol 716 ◽  
pp. 708-712 ◽  
Author(s):  
Peter Bella ◽  
Pavol Buček ◽  
Martin Ridzoň ◽  
Milan Mojžiš ◽  
Ľudovít Parilák
Keyword(s):  
Numerical Simulation ◽  
Cold Drawing ◽  
Point Of View ◽  
Tool Geometry ◽  
Drawing Process ◽  
Drawing Force ◽  
Steel Tubes ◽  
Physical Point ◽  
Cold Forming ◽  
Die Geometry

In Železiarne Podbrezová, cold drawing process is the final process in production of precision seamless steel tubes. This particular technology utilizes multiple drawing sequences and intermediate annealing. From the physical point of view, it is nothing just the optimal use of plastic deformation during cold forming that grants the final tube dimensions. The drawing process itself is significantly affected by physical and metallurgical properties of the tube, the tool geometry, the lubrication, and the sequence of operations. This paper deals with the relationship between the tool geometry and the drawing force. The FEM-based numerical model of the process was prepared in DEFORM 3D in order to optimize the geometry of the die; eight die geometries were investigated in total. The numerical simulation itself considered a hot rolled hollow at Ø32 mm × 4 mm, cold drawn into Ø25 mm × 4 mm using die drawing (sinking) sequences only. Calculated drawing force showed that the change of the run-in angle of the die led to a decrease of the drawing force.

FEM Simulation and Experimental Verification on Rotating Forging of Three-Layer Clad Cylinder Considering Constant Shear Friction

2012 ◽  
Vol 602-604 ◽  
pp. 2214-2218
Author(s):  
Gow Yi Tzou
Keyword(s):  
Finite Element ◽  
Velocity Field ◽  
Effective Strain ◽  
Fem Simulation ◽  
Interface Friction ◽  
Finite Element Software ◽  
Constant Shear ◽  
Element Simulation ◽  
Shear Friction ◽  
Forging Force

This study assumes the interface friction between dies and bounded three-layer clad cylinder as constant shear friction considering the rotation of three-layer bounded clad cylinder to establish the finite element simulation. The commercial finite element software (SUPERFORM) is used to explore effectively the effective stress, effective strain, and velocity field, forging force, and rotating torque in the three-layer clad cylinder rotating forging. Moreover, the rotating forging experiment of the three-layer clad cylinder is carried out practically to measure the forging force and the outer surface of three-layer clad cylinder. Forging force between analysis and experiment are compared to verify the acceptance of FEM simulation. This study can be offered to industries for technology establishment of rotating forging.

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